Power tool with battery pack ejector

ABSTRACT

A power tool has a mechanism for ejecting a battery pack which includes a receiving frame which defines a cavity to receive a battery pack. A receiving member is adjacent the cavity. The receiving member meshes with a member on the battery pack to hold the battery pack in the cavity. A biasing member is in the cavity adjacent the receiving member. The biasing member ejects the battery pack from the ejecting mechanism. A member retains the biasing member in the cavity. The member guides a portion of the battery pack meshing with the receiving member into contact with the biasing member such that when the battery pack is locked onto the frame, the biasing member is in a compressed condition and when the battery pack is an unlocked position, the biasing member ejects the battery pack from the frame.

FIELD AND BACKGROUND OF THE INVENTION

[0001] The present invention relates to power tools and, moreparticularly, to battery operated power tools which include a mechanismfor ejecting the battery from the tool.

[0002] In the power tool field, as battery technology improves,tradesmen are turning to battery operated tools. As the tradesmenutilize the battery operated tools, they desire tools with increasedpower, extended battery life, and longer durability. However, astradesmen require more power and extended battery life, battery size andweight increase. As this occurs, it is desirable to have additional helpto eject the batteries from the power tools.

[0003] Various types of battery ejectors exist in the field. Ordinarily,the batteries are surrounded by the housing and the biasing mechanismapplies a force on the battery or battery pack near the electricalcontact area. This is illustrated in U.S. Pat. No. 4,146,682 to Nakao;U.S. Pat. No. 5,681,667 to Bunyea et al; U.S. Pat. No. 5,225,293 toMitchell et al; and U.S. Pat. No. 5,637,417 to Engmark et al.

[0004] U.S. Pat. No. 6,223,835 to Habedank et al, which is assigned tothe assignee of the present invention, discloses a mechanism forassisting an ejecting battery from a power tool. The mechanism includesa cap which is biased by a spring or springs which are positioned withinthe housing. The cap acts upon the battery to apply a removal force ontothe battery. Here, the top of the battery and the end of the battery aresurrounded by the power tool housing.

[0005] The cited art does not provide a solution for ejecting a batterywhich is freely suspended by its coupling mechanism. In this case, thebattery is supported on only one side and the remaining battery extendsfrom the housing of the power tool. The majority of battery ejectors forthese types of batteries are like those illustrated in U.S. Pat. No.5,213,913. Here, the latching mechanisms, when moved, allow gravity todrop the battery from the housing. Thus, there was no need for a biasingforce to remove the battery pack from the tool housing.

SUMMARY OF THE INVENTION

[0006] The present invention provides the art with a battery ejectionmechanism which is utilized on batteries which are suspended from thepower tool. The suspended battery includes rails which enable thebattery to slide onto the power tool. The biasing member is positionedadjacent to the battery rails for ejecting the battery. Also, thebiasing member is positioned in alignment such that the biasing membercontacts the face of the rail mechanism of the battery to eject thebattery. The battery is partly ejected from the tool housing so that itcan be removed from the housing.

[0007] In accordance with a first aspect of the present invention, amechanism for ejecting a battery comprises a frame with a cavity in theframe to receive a battery pack. A receiving member extends from theframe and is adjacent the cavity. The receiving member meshes with amember on the battery pack to maintain the battery pack in the cavity. Abiasing member is positioned in the cavity adjacent the receivingmember. The biasing member ejects the battery pack from the ejectingmechanism. A member to retain the biasing member in the cavity issecured to the frame. The member guides the meshing portion of thebattery pack with the receiving member into contact with the biasingmember such that when the battery pack is locked onto the frame, thebiasing member is in a compressed condition and when the battery pack isin an unlocked positioned the biasing member ejects the battery packfrom the frame. The cavity is defined by a pair of opposing side wallsand an end wall adjoining the opposing side walls and an end walladjoining the opposing side walls. The receiving member includes a pairof rails extending from each side wall. The rails oppose one another.Channels are formed adjacent the side walls and between the rails andframe to receive mating rails on the battery pack. The biasing retainingmember is adjacent the channel. The biasing retaining member is a tabextending from the side wall of the frame. The biasing member includes apair of helical springs. The helical springs extend from the end walland are aligned coincident with the channel.

[0008] In accordance with a second aspect of the invention, a power toolcomprises a housing with a motor in the housing. An output is coupledwith the motor. An activation member is included to activate the motor.A mechanism on the housing receives a battery pack. The mechanismincludes a frame, with a receiving member and an adjacent cavity. Thereceiving member meshes with a member on the battery pack to hold thebattery pack in the cavity. A biasing member is positioned in the cavityadjacent the receiving member. The biasing member ejects the batterypack from the ejecting mechanism. A member to retain the biasing memberin the cavity is secured to the frame. The member guides the meshingportion of the battery pack with the receiving member into contact withthe biasing member such that when the battery pack is locked onto theframe, the biasing member is in a compressed condition and when thebattery pack is in an unlocked positioned the biasing member ejects thebattery pack from the frame. The cavity is defined by a pair of opposingside walls and an end wall adjoining the opposing side walls. Thereceiving member includes a pair of rails extending from each side wall.The rails oppose one another. Channels are formed adjacent the sidewalls and between the rails and frame to receive mating rails on thebattery pack. The biasing retaining member is adjacent the channel. Thebiasing retaining member is a tab extending from the side wall of theframe. The biasing member includes a pair of helical springs. Thehelical springs extend from the end wall and are aligned coincident withthe channel. A battery pack is received in the battery pack receivingmechanism. The battery pack includes a pair of rails mating in thechannels. The battery pack rails include an upper portion and a lowerportion and a channel between the upper and lower portions. Theextending tabs extend into the channel of the battery pack rails. Thebattery pack rails include end faces that abut the helical springs. Thebattery rails slide in the channels and the frame rails freely suspendthe battery pack from the tool housing. The helical springs arepositioned in the tool electrical connector housing.

[0009] From the following detailed description, taken in conjunctionwith the drawings and subjoined claims, other objects and advantages ofthe present invention will become apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a bottom perspective view of a power tool in accordancewith the present invention.

[0011]FIG. 2 is a side perspective view of the battery receivingmechanism of the drill of FIG. 1.

[0012]FIG. 3 is an enlarged perspective view of a portion of thereceiving element of FIG. 2.

[0013]FIG. 4 is a cross-section view of FIG. 1.

[0014]FIG. 5 is a perspective view of the battery removed from the tool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Turning to the figures, particularly FIG. 1, a power tool isillustrated and designated with the reference numeral 10. The power tool10 includes a housing 12 which includes a motor portion 14 and a handleportion 16 as well as a base portion 18. A motor 20 is positioned in thehousing 12. An output 22 is coupled with the motor 20 and in this caseincludes a chuck 24. An activation member 26 is positioned on the handleportion. The activation member is electrically coupled with the motor 20as well as with a battery pack 30 which supplies the power to the powertool 10.

[0016] The housing base portion 18 includes a battery pack receivingframe 32. The battery pack receiving frame 32 includes a pair ofopposing side walls 34 and 36 as well as an end wall 38. The side walls34, 36 and end wall 38 define a battery receiving cavity 40. The cavity40 is limited on the frame by a top wall or base 42. Each side wall 34,36 includes a rail 44, 46. The rails 44, 46 extend longitudinally alongthe frame from an end of the housing base portion 18 towards the endwall 38. Channels 48, 50 are formed between the rails 44, 46 and the topwall 42. The channels 48, 50 receive the battery pack 30.

[0017] An electrical connector housing 52 is coupled with the housingbase portion 18 adjacent the end wall 38. The electrical connectorhousing 52 includes electrical connectors 54, 56 which couple withelectrical connectors of the battery pack 30. The electrical connectorhousing 52 includes bores 58, 60 which receive helical springs 62, 64.Spring guides 66, 68 are positioned at the bottom of the bores 58, 60 toguide the helical springs 62, 64. Also, the guides 66, 68 maintain thesprings in the bores 58, 60 during assembly. Tabs 70, 72 extend from theside walls 34, 36 of the receiving frame 32. The tabs 70, 72 capture thehelical springs 62, 64 to maintain the springs 62, 64 in the bores 58,60. The tabs 70, 72 are positioned between the rails and the top wall 42aligned with the channels 48, 50 as seen in FIG. 3. The tabs 70, 72 aretapered from the frame 32 to the free end. Also, the tabs 70, 72 aretapered along their thickness as seen in FIGS. 3 and 4. The tapersassist in guiding the battery pack 30.

[0018] The battery pack 30 includes a housing 74 with a plurality ofbatteries (not shown) positioned within the housing. A release button 76which is coupled with a latch 78 is positioned on the housing 74. Thelatch 78 secures the battery pack 30 to the top wall 42 of the housingbase portion 18. The battery housing 74 includes rails 80, 82longitudinally extending along the top surface of the battery pack 30.The rails define channels 84, 86 which mesh with the rails 44, 46 of thehousing base portion 18. The rails 80, 82 include upper surfaces 88, 90and lower surfaces 92, 94. The upper and lower surfaces define channels96, 98. The rails 80, 82 are received in the channels 48, 50 of thehousing base receiving frame 32. The battery pack 30 includes electricalconnectors 104, 106. The electrical connectors 104, 106 are received inthe electrical connectors 54, 56 for powering the power tool 10.

[0019] The battery pack 30 is coupled with the housing receiving frame32 as follows. The battery pack rails 80, 82 are positioned in the framechannels 48, 50. The battery pack 30 is slid, rail upon rail, into thereceiving frame 32 until the latch 78 secures in a catch 79 in the topwall 42. As this occurs, the battery rail faces 100, 102 abut thehelical springs 62, 64. Prior to this happening, the battery railchannels 96, 98 receive the extending tabs 70, 72. The tabs 70, 72 guidethe rails 80, 82 into contact with the springs 62, 64. The contacting ofthe springs 62, 64 by the battery rail faces 100, 102 occurs prior tothe latch locking in the catch of the top wall 42. Accordingly, thesprings 62, 64 compress into the bores 58, 60.

[0020] To release the battery pack 30 from the power tool 10, the button76 is moved downwardly. As this occurs, the latch 78 also movesdownwardly removing the latch from the catch 79 on the top wall 42. Asthis occurs, the battery pack 30 is no longer locked in position on thepower tool housing receiving frame 32. At that time, the springs 62, 64,which are designed to have enough force to overcome the weight of thebattery pack 30 and the terminal friction, eject the battery pack 30away from the electrical connector housing 52. The battery pack 30 isejected partially from the battery pack receiving frame 32. Also, theejection disconnects the battery pack from the terminals.

[0021] While the above detailed description describes the preferredembodiment of the present invention, the invention is susceptible tomodification, variation and alteration without deviating from the scopeand fair meaning of the subjoined claims.

1-22 Cancelled.
 23. A power tool housing have a mechanism for ejecting abattery pack, comprising: a frame; a cavity in said frame for receivinga battery pack; a member for receiving a member on the battery pack tocouple the battery pack with the power tool; a biasing member in saidcavity, said biasing member for ejecting said battery pack from saidreceiving member; and a mechanism for retaining said biasing member insaid cavity, and said battery pack received in said receiving member sothat said battery pack is in contact with said biasing member such thatwhen the battery pack is secured on said frame, said biasing member isin a compressed condition and when the battery pack is released fromsaid frame, said biasing member ejects the battery pack from the frame.24. The ejector mechanism according to claim 23, wherein said cavitydefined by a pair of opposing side walls and an end wall adjoining saidopposing side walls.
 25. The ejector mechanism according to claim 24,wherein said receiving member including a pair of extending rails oneach side wall, said rails opposing one another.
 26. The ejectormechanism according to claim 25, wherein channels are formed adjacentsaid side walls and between said rails and frame for receiving matingrails on the battery pack.
 27. The ejector mechanism according to claim23, wherein said biasing member including at least one helical spring.28. The ejector mechanism according to claim 23, wherein said biasingmember extending from said end wall.
 29. A power tool, comprising: abattery pack; a housing; a motor in said housing; an output coupled withsaid motor; an activation member for activating said motor; a mechanismon said housing for receiving a battery pack including: a frame; acavity in said frame for receiving a battery pack; a member forreceiving a member on the battery pack to couple the battery pack withthe housing; a biasing member in said cavity, said biasing member forejecting said battery pack from said housing; and a mechanism forretaining said biasing member in said cavity, and the battery packreceived in said receiving member so that the battery pack is in contactwith said biasing member such that when the battery pack is secured onsaid housing, said biasing member is in a compressed condition and whenthe battery pack is released from the housing, said biasing memberejects the battery pack from the frame.
 30. The power tool according toclaim 29, wherein said cavity defined by a pair of opposing side wallsand an end wall adjoining said opposing side walls.
 31. The power toolaccording to claim 30, wherein said receiving member including a pair ofextending rails on each side wall, said rails opposing one another. 32.The power tool according to claim 31, wherein channels are formedadjacent said side walls and between said rails and frame for receivingmating rails on the battery pack.
 33. The power tool according to claim29, wherein said biasing member including at least one helical spring.34. The power tool according to claim 30, wherein said biasing memberextending from said end wall.
 35. The power tool according to claim 29,wherein said battery pack including a pair of rails mating in saidchannels.
 36. The power tool according to claim 35, wherein said batterypack rails including an upper portion, lower portion and a channelbetween said upper and lower portions.
 37. The power tool according toclaim 29, wherein said at least one helical spring partially ejects saidbattery pack.
 38. The power tool according to claim 35, wherein saidbattery rails slide in said channels and said frame rails suspend saidbattery pack from said tool housing.